Design parameter optimization of a membrane reactor for methanol synthesis using a sophisticated CFD model

Abstract

Carbon capture and utilization technologies are considered crucial in reducing carbon dioxide levels in the atmosphere and mitigating climate change. One of the most promising utilization options is the catalytic hydrogenation of the captured carbon dioxide to methanol. However, this reaction requires large energy-consuming recycles due to the limitation of the chemical equilibrium. To shift the chemical equilibrium and increase per-pass conversion, membrane reactors that remove the produced water from the reaction zone can be applied. A sophisticated CFD model of the membrane reactor with a NaA zeolite membrane is developed, to identify key constructive and operating parameters. The model implements the Maxwell–Stefan approach for permeation that considers the complex behavior of pervaporating water–alcohol mixtures through microporous zeolite membranes. In a full-factorial design of experiment, two general categories of parameters (ratio between reaction and permeation, permeation driving force) that influence conversion and yield in membrane reactors are identified that need to be optimized in construction and operation. In the most promising configuration, the application of the membrane reactor results in an increased CO₂ conversion of 20.6% and a 16.0% enhanced methanol yield compared to an equivalent conventional reactor. With the findings of this study, key parameters for the general optimization of the construction and operation of membrane reactors for industrial applications are identified.